Buderus 600-19R, 600-11R, 600-24R, 600 Series, 11R Installation And Servicing Instructions
...
7212 2900 - 05/2004 GB(EN) For trade use
Installation and servicing
instructions
Wall-mounted condensing gas boiler
Buderus 600 - 11R / 19R / 24R
Please read thoroughly before installing or servicing
The boiler meets the basic requirements of the
appropriate standards and directives.
Conformity has been substantiated by the proper
documents which - together with the declaration of
conformity - are filed with the manufacturer.
Buderus 600 Series
CE-0063BO3062
CE-0063BO3062
Subject to technical modifications!
Constant development efforts may result in minor deviations in
illustrations, functional steps and technical data.
Updating the documentation
If you have suggestions for improvement or have found
discrepancies, please do not hesitate to contact us.
Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk
2 Installation and servicing instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004
Contents
1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Dimensions and connections . . . . . . . . . . . . . . . . . 9
1.2 Boiler assembly - exploded view . . . . . . . . . . . . . 10
1.3 Flue Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 Items supplied with unit . . . . . . . . . . . . . . . . . . . . 13
1.5 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.6 Pipe connections . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.7 Flue installation . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.8 Electrical connections. . . . . . . . . . . . . . . . . . . . . . 17
1.9 Timing and temperature control . . . . . . . . . . . . . . 19
2 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.1 Preparing the boiler for operation. . . . . . . . . . . . . 20
3 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.1 Preparing the heating boiler for inspection . . . . . . 26
4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.1 Clean the heat exchanger, burner and
condensate trap . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.1 Operating codes . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.2 Fault codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.3 Checking and replacing parts. . . . . . . . . . . . . . . . 40
6 Conversion to another type of gas. . . . . . . . . . 48
7 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.1 Technical specifications . . . . . . . . . . . . . . . . . . . . 50
7.2 Short list of spare parts . . . . . . . . . . . . . . . . . . . . 52
8 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.1 Start-up report . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.2 Inspection and maintenance reports . . . . . . . . . . 54
Preface
These installation and servicing instructions apply to:
Buderus wall-mounted condensing gas boilers
600 - 11R / 19R / 24R.
Model: C13, C33, C
Type: GB II
Fuse rating: 1.25 Ampere slow blow
Power rating: 230 VAC, 50 Hz, IPX4D
Important general instructions for use
Only use the boiler in accordance with its designated use and
the installation and servicing instructions. Servicing and repair
must be carried out by CORGI registered installer. Only use
the boiler in combinations and with the accessories and spare
parts indicated in the installation and servicing instructions.
Other combinations, accessories and consumables may only
be used if they are expressly provided for the designated use
and if system performance and safety are not affected in any
way.
The boiler is suitable for connection to fully pumped, open
vented or sealed water systems.
Adequate arrangements for completely draining the system by
provision of draining valves must be provided in the installation
pipework.
Subject to technical modifications.
As a result of our policy of constant development, there may be
small differences between illustrations, functional steps and
technical data.
53
20 mbar, 37 mbar
2H3P
G. C. Aplliance No. :
Buderus 600 - 11R 41-110-21
Buderus 600 - 19R 41-110-22
Buderus 600 - 24R 41-110-23
BENCHMARK' Log Book
All Boulter Buderus gas fired boilers now include an installation, commissioning and service record log book. The details
of the log book will be required in the event of any warranty
work being requested.
Please complete the appropriate sections on completion of the
installation and commissioning.
REMEMBER: Please hand the log book back to the user.
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Installation and maintenance instructions wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 3
Regulations and directives
It is law that all gas appliances are installed and serviced by a
CORGI registered installer in accordance with the regulations.
Failure to install appliances correctly could lead to prosecution.
It is in your own interest, and that of safety, to ensure the law
is complied with.
The installation must also be in accordance with the latest
I.E.E (BS.7671) Wiring Regulations, local building regulations,
water regulations, the building regulations and the Building
Standards (Scotland) and any relevant requirements of the
local authority.
Detailed recommendations are contained in the following
British Standard Codes of Practice:
BS. 5440:1 Flues (for gas appliances of rated input not
exceeding 70 kW).
BS. 5440:2 Ventilation (for gas appliances of rated input not
exceeding 70 kW).
BS. 5449 Forced circulation hot water systems.
BS. 5546 Installation of gas hot water supplies for domestic
purposes (2nd. family Gases).
BS. 6798 Installation of gas fired hot water boilers of rated
input not exceeding 60 kW.
BS. 6891 Low pressure installation pipes.
IGE/UP/1b Tightness testing and purging domestic sized gas
installations.
Health and & Safety Document No. 635.
The Electricity at Work Regulations, 1989.
The manufacturer's notes must not be taken, in any way, as
overriding statutory obligations.
The design and construction of the Buderus wall-mounted
condensing gas boiler 600 - 11R/19R/24R conforms to the
basic specifications listed in the European directive governing
gas-fired appliances 90/396/EEC, and with respect to EN 625,
EN 483 and EN 677.
NOTE
Observe the corresponding technical rules and
the building supervisory and statutory
regulations when installing and operating the
system.
WARNING!
Keep the burner-control unit housing CLOSED
when working on water-bearing components.
NOTE
It is mandatory to clean and service the system
once a year. This includes an inspection of the
entire system to see if it is in full working order.
Defects and faults must be eliminated
immediately.
NOTE
When instructions aren’t followed, warranty
expires.
Timber Framed Buildings
If the boiler is to be fitted in a timber framed building it should
be fitted in accordance with the Institute of Gas Engineering
document IGE/UP/7:1998.
Bathroom Installations
This appliance is rated IPX4D.
The boiler may be installed in any room or internal space,
although particular attention is drawn to the requirements of
the current IEE (BS.7671) Wiring Regulations and, in
Scotland, the electrical provisions of the building regulations
applicable in Scotland, with respect to the installation of the
boiler in a room or internal space containing a bath or shower.
If the appliance is to be installed in a room containing a bath or
shower then, providing water jets are not going to be used for
cleaning purposes (as in communal baths/showers), the
appliance can be installed in Zone 3, as detailed in BS.7671.
Compartment Installations
A compartment used to enclose the boiler should be designed
and constructed especially for this purpose.
An existing cupboard or compartment may be used, provided
that it is modified for the purpose.
In both cases, details of essential features of cupboard/
compartment design, including airing cupboard installation,
are to conform to the following:
BS 6798 (No cupboard ventilation is required - see 'Air Supply'
for details).
It is not necessary to have a purpose-provided air vent in the
room or internal space in which the boiler is installed. Neither
is it necessary to ventilate a cupboard or compartment in which
the boiler is installed, due to the low surface temperatures of
the boiler casing during operation; therefore the requirements
of BS 6798, Clause 12, and BS 5440:2 may be disregarded.
The position selected for installation MUST allow adequate
space for servicing in front of the boiler.
For the minimum clearances required for safety and
subsequent service, see the wall mounting template.
In addition, sufficient space may be required to allow lifting
access to the wall mounting plate.
Wall-mounted condensing gas boilers must only be operated
with the combustion air/flue gas systems especially devised
and authorised for this type of boiler.
Observe the relevant standards, regulations and legislation of
the country of final use.
CAUTION
Use this device for its intended purpose only.
Subject to modifications resulting from technical improvements! Boulter Buderus Ltd. • http://www.boulter-buderus.co.uk
4 Installation and maintenance instructions wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004
DANGER!
Notes relating to the heating system water.
Thoroughly flush the system before it is filled
with water. Use only untreated water or water
treatment product such as Sentinal X100 to fill
and top up the system.
When using water treatment, only products
suitable for use with Boulter Buderus heat
exchangers are permitted (e.g. Sentinel X100).
Your warranty is at risk if an incorrect water
treatment product is used in conjunction with
this appliance. For more information, contact
Boulter Buderus Product Support Department.
It is most important that the correct
concentration of the water treatment product is
maintained in accordance with the
manufacturer's instructions.
If the boiler is used in an existing system any
unsuitable additives MUST be removed by
thorough cleaning. BS.7593:1992 details the
steps necessary to clean a domestic central
heating system.
In hard water areas, treatment to prevent lime
scale may be necessary - however, the use of
artificially softened water is NOT permitted.
Under no circumstances should the boiler be
fired before the system has been thoroughly
flushed.
Do not use water softened in a salt bedding
exchanger.
Do not use anti-freeze or other additives.
The expansion vessel must be of sufficient
size.
When oxygen-permeable pipes are used (e. g.
for floor heating systems) the system must be
separated by means of heat exchangers.
Unsuitable heating water promotes sludge
formation and corrosion. This may cause
malfunctions and damage in the heat
exchanger.
This appliance is not suitable for gravity
central heating nor are they suitable for the
provision of gravity domestic hot water.
The boiler must be vented.
Drain cocks must be located in accessible
positions, which permits the draining of the
entire system. They should be at least ½" BSP
nominal size and be in accordance with
BS. 2879.
The hydraulic resistance of the boilers is
shown in the graph below.
graph 1
350
300
250
200
150
resistance (mbar)
100
50
0
0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1 1,1 1,2 1,3
flow (m /h)
resistance heat exchanger
3
NOTE:
Notes relating to domestic hot water.
The boiler must not be used for direct hot water
supply.
The hot water storage cylinder must be of the
indirect type.
Single feed, indirect cylinders are not
recommended and must not be used on sealed
systems.
The hotwater cylinder and ancillary pipework,
not forming part of the useful heating surface,
should be lagged to prevent heat loss and any
possible freezing - particularly wher pipes run
throughroof spaces and ventilated underfloor
spaces.
The domestic hot water service must be in
accordance with BS 5546 and BS 6700.
Safe handling of substances
Care should be taken when handling the boiler's insulation,
which can cause irritation to the skin.
No asbestos, mercury or CFCs are included in any part of the
boiler and its manufacture.
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Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 5
Open vent system requirements
The system should be vented directly off the boiler flow pipe, as
close to the boiler as possible. The cold feed entry should be
inverted and MUST be positioned between the pump and the vent,
and not more than 150 mm (6") away from the vent connection.
NOTE
Combined feed and vent pipes may also be
fitted.
Feed / expansion
cistern
Wate r
level
(cold)
22 mm
open vent
15 mm
cold
feed
450 (18")
minimum
1000 (40")
minimum
150 (6")
max.
There should be a minimum height, 450 mm (18"), of open vent
above the cistern water level. The vertical distance between the
highest point of the system and the feed/expansion cistern water
level MUST not be less than 1000 mm (40"). The pump must be
fitted on the flow side of the boiler.
A suitable pump is a domestic circulator capable of providing a
maximum 11 °C (20 °F) temperature differential across the boiler
with the whole of the heating circuit open. With the minimum flow
circuit allowed by the controls the differential must not exceed
25 °C (see also the graph on page 5).
The vertical distance between the pump and feed/expansion
cistern MUST comply with the pump manufacturer’s minimum
requirements, to avoid cavitation. Should these conditions not
apply either lower the pump position or raise the cistern above the
minimum requirements specified by Boulter Buderus. The
isolation valves should be fitted as close to the pump as possible.
Schematic pipework and system balancing
The boiler does not normally need a bypass but at least some
radiators on the heating circuit, of load at least 10% of the
minimum boiler output, must be provided with twin lockshield
valves so that this minimum heating load is always available (see
footnote re. thermostatic radiator valves).
Balancing
1. Set the programmer to ON for both CH and HW. Turn the
cylinder thermostat down. Close the manual or thermostatic
valves on all radiators leaving the twin lockshield valves (on
the radiators referred to above) in the open position. Turn up
the room thermostat and adjust these lockshield valves to give
boiler flow and return temperatures not more than 20 °C apart.
These valves should now be left as set.
2. Open all manual or thermostatic radiator valves and adjust the
lockshield valves on remaining radiators to give around 11 °C
temperature drop at each radiator.
3. Turn up the cylinder thermostat and adjust the cylinder
balancing valve so that the cylinder achieves a maximum flow
consistent with adequate flow to the radiators. Check that with
only the domestic hot water loop in circuit a differential
temperature of 20 °C across the boiler is not exceeded.
4. Adjust room and cylinder thermostats and programmer to
NORMAL settings.
System
flow to
pump
Connection
to boilers
fig. 1 Open vent system
22 mm
open vent
15 mm
cold
feed
Elbow
then
tee
Flow
Return
BOILER
fig. 2 Schematic pipework and system
System
return
Air vent
Alternative
2x2 port
valves
Radiators
Inverted cold
feed entry
3 port
valve
Cylinder
balancing
valve
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6 Installation and maintenance instructions wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004
Thermostatic radiator valves
k
Boulter Buderus support the recommendations made in
BS. 5449, and by leading manufacturers of domestic heating
controls, that heating systems utilising the thermostatic
radiator valve control of temperature in individual rooms shall
also be fitted with a room thermostat, controlling the
temperature in a space served by radiators not fitted with such
a valve.
Such an arrangement will provide for potentially more efficient
control of the environment and will also avoid the continuous
running of the circulation pump during programmed heating
ON periods - thus saving electrical energy.
It is, therefore, strongly recommended that, when thermostatic
radiator valves are used, space heating temperature control
over a living/dining area or a hallway having a heating
requirement of at least 10% of the minimum boiler heat output,
is achieved using a room thermostat whilst other rooms are
individually controlled by thermostatic radiator valves.
Sealed system requirements
NOTE
The method of filling, refilling, topping up or
flushing sealed hot water circuit from the mains
via a temporary hose connection is only
allowed if acceptable to the local water
authority.
1. General
The installation must comply with the requirements of
BS. 6798 and BS. 5449.
The installation should be designed to work with flow
temperatures of up to 80 °C.
All components of the system, including the heat exchanger of
the indirect cylinder, must be suitable for a working pressure of
3 bar (45 lb/in
2
) and temperature of 110 °C. Care should be
taken in making all connections so that the risk of leakage is
minimised.\
2. Safety valve
A spring loaded safety valve complying with the relevant
requirements of BS. 6759 must be fitted in the flow pipe as
close to the boiler as possible and with no intervening valve or
restriction. The valve should have the following features:
– A non-adjustable preset lift pressure not exceeding 3 bar
(45 lb/in
2
);
– A manual testing device;
– Provision for connection of a discharge pipe. The valve or
discharge pipe should be positioned so that the discharge
of water or steam cannot create a hazard to the occupants
of the premises or cause damage to electrical components
and wiring.
Make-up vessel
(max. capacity 3 litres)
Hose union
bib tap
Water
supply
Hose connector
Nonreturn
valve
Automatic
air vent
Hosepipe
(disconnect
after refilling)
BS. 1010:2
stop tap
HEATING
CIRCUIT
Test cock
Air vent
Pump
Double check valve
Pressure gauge
Expansion
vessel
Safety valve
BOILER
Drain coc
fig. 3 Sealed system
3. Pressure gauge
A pressure gauge covering at least the range of 0-4 bar
(0-60 lb/in
2
) must be fitted to the system. The gauge should be
easily seen from the filling point and should preferably be
connected at the same point as the expansion vessel.
4. Expansion vessel
A diaphragm type expansion vessel must be connected to a
point close to the inlet side of the pump, the connecting pipe
being not less than 15 mm (½" nominal) size and not
incorporating valves of any sort.
The vessel capacity must be adequate to accept the
expansion of the system water when heated to 110 °C
(230° F).
The charge pressure must not be less than the static water
head above the vessel. The pressure attained in the system
when heated to 110 °C (230° F) should be at least 0.35 bar
2
(5 lb/in
) less than the lift pressure of the safety valve.
For guidance on vessel sizing refer to table 1.
For further details refer to BS. 5449 and BS. 7074:1 and the
British Gas Corporation publication: "Material and Installation
Specifications for Domestic Central Heating and Hot Water".
5. Cylinder
The cylinder must be either of the indirect coil type or a direct
cylinder fitted with an immersion calorifier which is suitable for
operating on a gauge of 0.35 bar (5 lb/in
2
) in excess of the
safety valve setting. Single feed indirect cylinders are not
suitable for sealed systems.
6. Make-up water
provision must be made for replacing water loss from the
system, either:
– from a manually filled make-up vessel with a readily visible
water level. The vessel should be mounted at least 150 mm
(6") above the highest point of the system, and be
connected through a non-return valve to the system, filled
at least 300 mm (12") below the make-up vessel on the
return side of the domestic hot water cylinder or radiators.
or
– where access to a make-up vessel would be difficult by
pre-pressurisation of the system. Refer to "Filling", below.
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Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 7
7. Mains Connection
There must be no direct connection to the mains water supply
or to the water storage tank supplying domestic water, even
through a non-return valve, without the approval of the local
water authority.
8. Filling
The system may be filled by one of the following methods:
a. Through a cistern, used for no other purpose, via a ball
valve permanently connected directly to a service pipe
and/or a cold water distributing pipe. The static head
available from the cistern should be adequate to provide
the desired initial system design pressure. The cold feed
pipe from the cistern should include a non-return valve and
a stop valve with an automatic air vent connected between
them, the stop valve being located between the system and
the automatic air vent. The stop valve may remain open
during normal operation of the system if automatic water
make-up is required.
b. Through a self-contained unit comprising a cistern,
pressure booster pump (if required) and, if necessary, an
automatic pressure reducing valve and flow restrictor. The
cistern should be supplied through a temporary connection
from a service pipe or cold water distributing pipe.
This unit may remain permanently connected to the
heating system to provide limited automatic water makeup. Where the temporary connection is supplied from a
service pipe or distributing pipe which also supplies other
draw-off points at a lower level then a double check valve
shall be installed upstream of the draw-off point.
c. Through a temporary hose connection from a draw-off tap
supplied from a servicing pipe under mains pressure.
Where the mains pressure is excessive a pressure
reducing valve shall be used to facilitate filling.
The following fittings shall form a permanent part of the system
and shall be fitted in the order stated:
– A stop valve complying with the requirements of
BS. 1010, Part 2 (the hose from the draw-off tap shall
be connected to this fitting);
– A test cock;
– A double check valve of an approved type.
z Thoroughly flush out the whole of the system with cold
water, without the pump in position.
z With the pump filled, fill and vent the system until the
pressure gauge registers 1.5 bar (21.5 lb/in
2
). Examine
for leaks.
z Check the operation of the safety valve by manually
raising the water pressure until the valve lifts. This
should occur within ± 0.3 bar (4.3 lb/in
2
) of the preset lift
pressure.
z Release water from the system until the initial system
design pressure is reached.
z Light the boiler and heat the system to the maximum
working temperature. Examine for leaks.
z Turn off the boiler and drain the system while still hot.
z Refill and vent the system.
z Adjust the initial pressure to the required valve.
Sizing procedure for expansion vessel
The volume of the expansion vessel (litres) fitted to a sealed
system shall not be less than that given by the table below,
multiplied by a factor of 0.8 (for flow temperatures of less than
80 °C).
Safety valve setting 3.0 bar 2.5 bar 2.0 bar
Vessel charge and initial system
pressure
Total water content of system (litres) Expansion vessel volume litres
25 2.1 2.7 3.9 2.3 3.3 5.9 2.8 5.0
50 4.2 5.4 7.8 4.7 6.7 11.8 5.6 10.0
75 6.3 8.2 11.7 7.0 10.0 17.7 8.4 15.0
100 8.3 10.9 15.6 9.4 13.4 23.7 11.3 20.0
125 10.4 13.6 19.5 11.7 16.7 29.6 14.1 25.0
150 12.5 16.3 23.4 14.1 20.1 35.5 16.9 30.0
175 14.6 19.1 27.3 16.4 23.4 41.4 19.7 35.0
200 16.7 21.8 31.2 18.8 26.8 47.4 22.6 40.0
225 18.7 24.5 35.1 21.1 30.1 53.3 25.4 45.0
250 20.8 27.2 39.0 23.5 33.5 59.2 28.2 50.0
275 22.9 30.0 42.9 25.8 36.8 65.1 31.0 55.0
300 25.0 32.7 46.8 28.2 40.2 71.1 33.9 60.0
Multiplying factors for other
system volumes
Table 1 Expansion vessel volumes
0.5 1.0 1.5 0.5 1.0 1.5 0.5 1.0
bar bar bar bar bar bar bar bar
0.0833 0.109 0.156 0.094 0.134 0.237 0.113 0.20
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8 Installation and maintenance instructions wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004
Installation 1
1 Installation
1.1 Dimensions and connections
CH FLOW
CH RETURN
460 mm (18")
290 mm (11,4")
105 mm (4")
230 mm (9")
50 (2")
70 (2.8")
130 (5")
145 (5,7")
619 mm (24")
604 mm (23,7")
Ø100 (4")
3
Ø60 (2 ")
328 mm (13")
376 mm (15")
25 mm (1")
8
20 (0.8")
700 mm (27½")
119 mm (4,7")
82 mm (3")
CWDO
GAS
CH Flow = Ø22 mm Compression (0.87")
CH return = Ø22 mm Compression (0.87")
GAS = Gas connection G½" INSIDE
CWDO = Condensate water drainage outlet Ø21.5 mm (0.8") OUTSIDE
NOTE
See the wall-mounting template for the necessary clearances.
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Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 9
Installation1
1.2 Boiler assembly - exploded view
Single unit (11R / 19R / 24R)
350
10
380
310
340
420
440
360
320
290
330
250
370
280
260
270
120
520
510
400
390
410
430
450
460
470
480
480
20
Legend
10. Casing
230
110
130
230
250
240
300
200
70
60
100
500
80
170
530
180
40
560
540
160
90
190
210
220
490
140
150
240
290
50
30
20. Door complete
30. Ventilation cover
40. Bracket
50. Concentric adaptor
60. Clip adaptor
70. Lipring 100mm
80. Fan
90. Sealing Fan / Venturi
100. Lipring 60mm
110. Flue gas pipe
120. Condensate collector
130. Seal flue gas pipe
140. Flue gas sensor
150. Condensate trap
160. Suction pipe
170. Lipring 50mm
180. Gas valve
190. Rectifier
200. Venturi
210. Gas pipe
220. Gas service valve
550
230. Pipe return/flow top
240. Pipe connection
250. Clip
260. Return pipe
270. Drain cock
280. Connection return
290. Sensor
300. Flow pipe
310. Connection supply
320. Hairpin heat exchanger
330. Automatic air vent
340. O-ring
350. Lipring
360. Safety sensor
370. Sealing ring
380. Backpart heat
exchanger
390. Seal heat exchanger
400. Insulation backpart heat
exchanger
410. Burner 11 kW
Burner 19 kW
Burner 24 kW
420. Sealing burner
430. Heat exchanger helix
440. Combustion divider
450. Insulation front heat exchanger
460. Frontpart heat exchanger
470. Sight glass
480. Fasteners
490. UBA
500. Main switch
510. Hot surface ignitor
520. Ionisation electrode
530. Cable fan
540. Cable harness
550. Frame
560. RTH converter 230V
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10 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004
Installation 1
1.3 Flue Installation
1.3.1 Siting the flue terminal
The flue must be installed in accordance with the
recommendations of BS. 5440-1:2000.
Pluming will occur at the terminal so terminal positions where
this could cause a nuisance should be avoided.
The air supply and the flue gas exhaust must meet the
applicable general regulations. Please consult the instructions
provided with the flue terminal kits prior to installation.
The boiler MUST be installed so that the terminal is exposed
to external air.
It is important that the position of the terminal allows the free
passage of air at all times.
Minimum acceptable spacing from the terminal to obstructions
and ventilation openings are specified in table 1.
If the terminal is fitted within 1000 mm of a plastic or painted
gutter or within 500 mm of painted eaves, an aluminium shield
of at least 1000 mm long should be fitted to the underside of
the gutter or painted surface.
If the lowest part of the terminal is less than 2 metres above the
level of the ground, balcony, flat roof or place to which any
person has access, the terminal must be protected by a guard.
Protective guards are available from Quinnell Barrett and
Quinnell, Old Kent Road, London.
Ensure that the guard is fitted centrally.
The flue assembly shall be so placed or shielded as to prevent
ignition or damage to any part of the building.
The air inlet/products outlet duct and the terminal of the boiler
MUST NOT be closer than 25 mm (1'') to combustible material.
Detailed recommendations on the protection of combustible
material are given in BS. 5440 - 1:2000.
NOTE
It is absolutely essential to ensure, in practice,
that products of combustion discharging from
the terminal cannot re-enter the building or any
other adjacent building through ventilators,
windows, doors, other sources of natural air
infiltration, or forced ventilation/airconditioning.
If this could occur the appliance MUST be turned off (with the
owners permission), and labelled as unsafe until corrective
action can be taken.
A
B,C
M
A
F
M
G
under carport
H, I
B,C
K
F
F
G
D
K
G
Fig. 1 Flue terminal position
Terminal Position
A. Directly below or alongside an opening
window, air vent or other ventilation opening
B. Below guttering, drain pipes or soil pipes
C. Below eaves
D. Below balconies or a car port roof
E. From vertical drain pipes or soil pipes
F. From internal or external corners
G. Above adjacent ground, roof or balcony level
H. From a surface facing the terminal
I. From a terminal facing a terminal
J. From an opening in a car port (e.g. door or
window) into dwelling
K. Vertically from a terminal on the same wall
L. Horizontally from a terminal on the wall
M. Adjacent to opening
C
K
L
L
K
G
FJ
Minimum
Spacing
300 mm (12")
75 mm (3")
200 mm (8")
200 mm (8")
150 mm (6")
300 mm (12")
300 mm (12")
600 mm (24")
1200 mm (48")
1200 mm (48")
1500 mm (60")
300 mm (12")
300 mm (12")
Table 1 Balanced flue terminal position
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Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 11
Installation1
1.3.2 Air supply and flue gas exhaust in a closed installation
A ventilation cover is integrated into the 600 Series condensing
gas boilers. This cover houses a number of components, such
as the burner and the heat exchanger. Since this ventilation
cover is part of the air supply system, it is vital that it is always
installed correctly.
To ensure optimal operation, the 600 Series appliances must
be connected to a Buderus wall-mounted or roof-mounted flue
terminal. These terminals have been developed specifically for
the 600 Series condensing gas boilers and have been
comprehensively tested. The Buderus wall and roof-mounted
flue terminal kits ensure trouble-free operation.
The following items for the flue (see fig. 2) are included in the
delivery of the boiler:
– pos. 1: 1 Concentric bend 60/100;
– pos. 2: 1 Horizontal flue terminal 60/100;
– pos. 3: 1 Flue finishing kit.
1.3.3 Maximum Flue length
The maximum pipe length of the air supply and flue gas
exhaust pipes for the 600 Series condensing gas boilers (see
table 2) is determined by the total pressure loss of all
components in the flue gas exhaust / air supply system.
1
Fig. 2 Horizontal flue pack
2
3
L
550 mm
50 mm
Take the flue conduit clearances into account when planning
the layout of the place of installation (see subsection 1.3.1:
"Siting the flue terminal" on page 11).
Maximum wall thickness without extensions is 550 mm.
Maintain a minimum side wall clearance of 50 mm (see fig. 3).
1.3.4 Additional flue parts
Additional flue parts (see table 3) can be ordered from your
supplier.
Fig. 3 Side flue and rear flue installation
Boiler
600 Series L = 7.5 m 1.2 m
Table 2 Pipe length
Flue parts Order No.
Concentric pipe, 500 mm long, adjustable NE 83703
Concentric pipe, 1000 mm long, not adjustable NE 83704
Concentric bend 90° NE 83705
Concentric bend 45° NE 83706
Table 3 Additional flue parts
Maximum
pipe length
For every 90° bend the
maximum pipe length has
to be reduced by
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12 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004
Installation 1
1.4 Items supplied with unit
z Check the contents against the packing list to ensure that
nothing is missing.
Key to fig. 4:
1: Wall-mounted condensing gas boiler
2: Wall bracket
3: Technical documents
4: CH Flow connection pipe
5: CH Return connection pipe
6: Gas service valve
7: Plastic bag containing the following accessories:
2 x wall fixing-screws
2 x wall plugs
2 x washers
Seals (2 x ¾“)
Square wrench
Initial start-up sticker
Second identification plate
Requirements to be met by the place of installation
NOTE
Observe all statutory building regulations
applying to the place of installation.
1
Fig. 4 Items supplied with unit
2
5
4
3
6
7
1
2
DANGER!
Inflammable materials or liquids must not be
stored or used near wall-mounted condensing
gas boilers. The site of installation must be
frost-protected.
1.5 Transport
The boiler is transported in a horizontal position.
z Open the box and remove the four foam supports (fig. 5,
item 1). The casing is not attached to the boiler.
z Take out the casing (fig. 5, item 2) and put aside during
installation.
CAUTION!
Do not carry the boiler by the casing at any
time.
z Take out the wall bracket (fig. 4, item 2) and attach to the
wall using the wall mounting template.
z Take out the condensing gas boiler (fig. 5, item 3) and
hang onto the wall bracket (fig. 6).
z Dispose of packaging.
3
Fig. 5 Unpacking the box
Fig. 6 Installation
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Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 13
Installation1
1.6 Pipe connections
CAUTION!
Ensure that all pipework is routed so as to
minimise any strain on the boiler fittings.
1.6.1 Gas Supply
The gas installation must be installed in accordance with
BS.6891.
CAUTION!
Pipework from the meter to the boiler MUST be
of adequate size.
The complete installation MUST be tested for gas tightness
and purged as described in IGE/UP/1b.
1.6.2 Gas connection
12
z A gas service valve is supplied with the unit. Take it out of
the box and connect it to the boiler see fig. 7, item 3 with
P.T.F.E.-tape. Connect to gas supply according to the
relevant standards.
1.6.3 Heating system connections
The central heating system should be in accordance with
BS.6798 and, in addition, for smallbore and microbore
systems, BS.5449.
z Take the CH flow connection pipe and the CH return
connection pipe out of the box and connect to the
condensing gas boiler see fig. 7, item 1 and 2.
z Connect the central heating system to these pipe
connections according to the relevant standards.
1.6.4 Condensate drain
A condensate drain is integrated in the boiler. The drain outlet
is a standard (21.5 mm) overflow pipe. This drain needs to be
connected to a drainage point. All pipework and fittings in the
condensate drainage system MUST be made of plastic - no
other materials may be used.
The routing of the drain must be made to allow a minimum fall
of 1 in 20 away from the boiler, throughtout its length.
4
Fig. 7 Pipe connections
Key to fig. 7:
1: CH flow
2: CH return
3: Gas
4: Condensate water drainage outlet (CWDO)
3
Excessive external pipe runs should be avoided in order to
prevent possible freezing.
Any external pipework should be a minimum of 32 mm internal
diameter.
WARNING!
Any external run must be insulated.
Ensure that the condensate trap is filled with water.
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14 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004
Installation 1
1.7 Flue installation
The only flue systems that may be used are those supplied by
Boulter Buderus. The flue system must be installed in
accordance with the requirements of BS.5440:1. 2000.
Standard 100 mm flue systems
The standard concentric flue system provides for a max.
horizontal straight length of upto 7.5 m (see subsection 1.3.3).
Full instructions for fitting this flue are in subsection 1.7.2:
"Installation of the horizontal flue" on page 15.
IMPORTANT
Any horizontal flue system fitted to a
condensing boiler must be inclined towards the
appliance at an angle of 3% (30 mm per metre
length) to prevent condensate dripping from
the flue terminal.
This means that the clearance above the
appliance must be increased to match the duct
length. See figure on page 9.
1.7.1 Connecting the vertical flue gas duct
z Fit the vertical flue gas duct (fig. 8) onto the appliance flue
connector.
z For remaining installation of the vertical flue assembly,
refer to the relevant installation instructions.
1.7.2 Installation of the horizontal flue
The standard 100 mm diameter horizontal flue system is
siutable for lengths upto 560 mm (see fig. 10).
For longer flue runs upto 7.5 m, extension air/flue ducts are
available (see page 12, table 3).
NOTE
Use the wall-mounting template to help you
mark the position of the side flue opening
Flue gas
testing point
Fig. 8 Vertical flue connection
Flue gas
testing point
Fig. 9 Elbow with flue gas testing point
Flue
Turret
Maximum 560 mm
No Clamp
Terminal
assembly
Outer
Wall
Fig. 10 Standard flue
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Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 15
Installation1
1.7.3 Flue duct preparation and assembly
z Measure the flue length L. Refer to figures 11 and 12.
NOTE
The flue must be inclined to the boiler.
z Mark of the lengths shown onto the ducts and cut the
length. The cuts must be square and free from burrs.
Terminal assembly outer (air) duct - L-70 mm, inner (flue)
duct - L-50 mm. The measurement is made from the ridge
at the terminal indicating the outer face of the wall.
Refer to figure 13.
Extension air duct - L-70 mm, flue duct - L-50 mm.
The measurement is from the formed end.
z Assemble flue system completely. Push the ducts fully
together. The slope of the terminal outlet must be face
downwards.
The assembly will be made easier if a solvent free grease
is lightly applied to the male end of the ducts.
NOTE
An inner wall sealing plate is provided which
should be fitted to the ducts before assembly.
L
105
Fig. 11 Flue length - rear
L
z Push the assembly through the wall and slide the turret
onto the flue connector. Refer to figure 9.
z Ensure that the turret is fully entered into the socket on the
boiler. From the outside fix the flue finishing kit to the
terminal and, after ensuring the duct is properly inclined
towards the boiler, fix the finishing kit to the wall.
If the terminal is within 2 m of the ground where there is
access then an approved terminal guard must be fitted.
The guard must give a clearance of at least 50 mm around
the terminal and be fixed with corrosion resistant screws.
Fig. 12 Flue length - side
Outer
Wall
Face
Fig. 13 Flue terminal position
Flue Terminal
Raised Ring
locating the
terminal relative
to the outside
wall face
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16 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004
Installation 1
1.8 Electrical connections
1.8.1 Mains connection
CAUTION
This appliance MUST be earthed.
A mains supply of 230 V - 50Hz is required.
External controls are suitable for volt free or 230 V installation.
Wiring to the boiler MUST be in accordance with the current
I.E.E. (BS.7671) Wiring Regulations and any local regulations.
Wiring should be a 3 core PVC insulated cable, not less than
0.75 mm
Connection must be made in a way that allows complete
isolation of the electrical supply such as a double pole switch
having 3 mm (1/8'') contact seperation in both poles, or a plug
and socket, serving only the boiler and system controls. This
boiler is equipped with a double pole switch see fig. 14, item 1.
The means of isolation must be accessible to the user after
installation.
The electrical connection to the mains supply should be readily
accessible and adjacent to the boiler.
If the supply cord is damaged, it must be replaced by a
registered Corgi installer to avoid a hazard.
2
(24 x 0.2 mm), and to BS.6500 Table 16.
1
Fig. 14 UBA
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Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004 17
Installation1
1.8.2 Wiring Diagram
4
12 3
18-pin connection strip
FS
FR
PA
Burner-control unit (UBA)
Flame-monitoring electrode
ignitor
Hot surface
STB
Fuse, main switch, emergency OFF switches and
safety measures to comply with local regulations and standards
port
I/O
Communication
24Vac
12 34
MV
1234
To Boiler
1234
RTH
321
Loop
1)
ON/OFF-
potential free
room thermostat
!
20-pin connection strip
KIM
FK
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
3
2
1
12 1 2
N
M
L
Ventilator
50 Hz
~
230V
Mains power source
Max. permitted
10A
fuse rating
STB Flue gas monitor
230Vac
321
230 Vac ON/OFF-
room thermostat
device may be connected.
FR Return-temperature sensor (return)
FS Safety-temperature sensor (safety)
FK Supply-temperature sensor (supply)
KIM Boiler identification module
MV Solinoid valve
Note:
1) Only one room-temperature regulating
IMPORTANT
The wires inthis mains lead are coloured in accordance with the following code:
GREEN AND YELLOW - EARTH ; BLUE - NEUTRAL ; BROWN - LIVE
As the colours of the wires in the mains lead of of the appliance may not correspond with the coloured markings identifying the terminals in your plug proceed as follows:
The wire coloured green and yellow must be connected to the terminal on the plug marked with the letter E or by the earth symbol or coloured green or green-and-yellow. The wire coloured brown must be connected to the terminal marked with
the letter L or coloured red. The wire coloured blue must be connected to the terminal marked with the letter N or coloured black.
FOR LOCATION OF INDIVIDUAL COMPONENTS, SEE TROUBLESHOOTING GUIDE IN THE SERVICE SECTION OF THIS MANUAL.".
WARNING
THIS APPLIANCE MUST BE EARTHED
Ensure that your appliance is connected correctly - if you are in any doubt consult a qualified electrician.
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18 Installation and maintenance instructions for wall-mounted condensing gas boiler Buderus 600 - 11R/19R/24R • 05/2004
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